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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Ultra-low radioactivity flexible printed cables

Abstract Flexible printed cables and circuitry based on copper-polyimide materials are widely used in experiments looking for rare events due to their unique electrical and mechanical characteristics. However, past studies have found copper-polyimide flexible cables to contain 400-4700 pg 238 U/g, 16-3700 pg 232 Th/g, and 170-2100 ng nat K/g, which can be a significant source of radioactive background for many current and next-generation ultralow background detectors. This study presents a comprehensive investigation into the fabrication process of copper-polyimide flexible cables and the development of custom low radioactivity cables for use in rare-event physics applications. A methodical step-by-step approach was developed and informed by ultrasensitive assay to determine the radiopurity in the starting materials and identify the contaminating production steps in the cable fabrication process. Radiopure material alternatives were identified, and cleaner production processes and treatments were developed to significantly reduce the imparted contamination. Through the newly developed radiopure fabrication process, fully-functioning cables were produced with radiocontaminant concentrations of 20-31 pg 238 U/g, 12-13 pg 232 Th/g, and 40-550 ng nat K/g, which is significantly cleaner than cables from previous work and sufficiently radiopure for current and next-generation detectors. This approach, employing witness samples to investigate each step of the fabrication process, can hopefully serve as a template for investigating radiocontaminants in other material production processes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Lack of robustness and accuracy of many numerical schemes for phase-field simulations

In this paper, we study the stability, accuracy and convergence behavior of various numerical schemes for phase-field modeling through a simple ODE model. Both theoretical analysis and numerical experiments are carried out on this ODE model to demonstrate the limitation of most numerical schemes that have been used in practice. One main conclusion is that the first-order fully implicit scheme is the only robust algorithm for phase-field simulations while all other schemes (that have been analyzed) may have convergence issue if the time step size is not exceedingly small. More specifically, by rigorous analysis in most cases, we have the following conclusions: (i) The first-order fully implicit scheme converges to the correct steady state solution for all time step sizes. In the case of multiple solutions, one of the solution branches always converges to the correct steady state solution. (ii) The first-order convex splitting scheme, which is equivalent to the first-order fully implicit scheme with a different time scaling, always converges to the correct steady state solution but may seriously lack numerical accuracy for transient solutions. (iii) For the second-order fully implicit and convex splitting schemes, for any time step size $δt > 0$, there exists an initial condition $u_0$ , with $|u_0| > 1$, such that the numerical solution converges to the wrong steady state solution. (iv) For $|u_0|$ ≤ 1, all second-order schemes studied in this paper converge to the correct steady state solution although severe numerical oscillations occur for most of them if the time step size is not sufficiently small. (v) An unconditionally energy-stable scheme (such as the modified Crank–Nicolson scheme) is not necessarily better than a conditionally energy-stable scheme (such as the Crank–Nicolson scheme). Finally, most, if not all, of the above conclusions are expected to be true for more general Allen–Cahn and other phase-field models.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

DESS (Differential Equation System Solver) [SWR-24-48]

The Differential Equation System Solver (DESS) is a Rust crate implementing fixed-step and adaptive-step solvers and designed especially for modeling physical systems. Seven explicit ordinary differential equation (ODE) solver methods have been added so far: Euler’s, Heun’s, Midpoint, Ralston’s, Classic Runge-Kutta, Bogacki-Shampine, and Cash-Karp. These comprise five fixed-step methods and two adaptive-step methods. Few solver packages are implemented in the Rust ecosystem and none are intended specifically for physical system modeling, so the goal of DESS is to create a Rust ODE solver crate designed to easily specify and model physical systems with modular, configurable solver options. In addition to allowing users to directly input equations to solve, DESS allows users to optionally specify and define relationships between nodes in their system, which the package then translates into a system of equations via the Rust macro system, leading to simpler and more intuitive code.

Steuteville, Robin↗
DOE OSTI2024

General Applications for Hamilton Vantage (GenApps for Vantage) v0.6.1

General applications for Hamilton Vantage is a flexible liquid handling method used to automate the most widely applicable types of automated liquid transfers. General applications can also be used as a tool to onboard new fully-automated workflows by breaking them down step by step into single transfers. The goal of General Applications is to make using the Hamilton Vantage liquid handler as easy & practical as using a handheld pipette for the end user. The software supports plate-to-plate transfers for a variety of method types including: Stamp: One-to-One, Stamp: One-To-Many, Split, Combine, Hitpick, and Qtray plating. General Applications eliminates the need for automation engineers to customize individual methods for each new workflow that gets onboarded. Steps can be customized within GenApps according to the needs of the researcher. The software utilizes a GUI to prompt the users to input variables – Allowing for flexible control over plate types, transfer volumes, number of replicates, tip types, liquid classes, mixing steps, aspiration/dispense heights and more. General Applications also generates a deck image and setup instructions to guide the researcher on how to load the deck and start the instrument.

Yoder, Sam↗
DOE OSTI2026

Evaluating isoprenol production using the IPP-bypass pathway in the oleaginous yeast Rhodosporidium toruloides

Background To strengthen the national energy supply, there is an increasing demand for domestically generated aviation fuels. Bio-derived advanced aviation fuels offer the opportunity to meet this domestic need while presenting a unique opportunity to investigate the production of novel aviation fuels. Isoprenol, a chemical precursor to such novel fuels, has been shown to be a biologically producible compound in model organisms, but its bio-producibility needs to be further explored in organisms more compatible with industrial bioproduction. Results In this work, we evaluate isoprenol production using the promising bioproduction yeast, Rhodosporidium toruloides. First, we show successful isoprenol production using the IPP-bypass pathways most successful in laboratory strains of E. coli and S. cerevisiae. Next, we demonstrate that increased flux through the mevalonate pathway only modestly increases isoprenol titers. Using proteomics, we identified a potential bottleneck in production at the final step in the IPP-bypass pathway and explored alternative enzymes for this step. Finally, the top three strains of R. toruloides were evaluated in sorghum hydrolysates generated using cholinium lysinate. Through this work, 93.1 mg/L of isoprenol was produced in mock medium and 27.3 mg/L in sorghum hydrolysates. Conclusion Together these results lay the foundation for future work for the production of isoprenol from bioproduction crops.

Advanced aviation fuel↗
DOE OSTI2024

Developing a remediation framework

When harmful contaminants are detected in soil, sediment, or groundwater (or suspected due to industrial activities), remediation efforts may be required to protect human health and the environment. This chapter will introduce and discuss the steps in the general site remediation process that are key when approaching any remediation strategy, regardless of the site complexity. While these steps are described in a linear fashion, in most cases, the approach is more fluid and iterative depending on the desired outcomes and success of each progressive clean-up effort along the way. This chapter will additionally articulate some key considerations which may be important to the overall remediation strategy depending on the particular needs and desired outcomes. From these more general discussions, the chapter will branch into a case-study of the remediation approach, or process steps, previously/currently/in the future taking place at the Hanford Site, as one example of a complex waste sites in the United States. As indicated earlier, while a remediation strategy can be more simply described by a progression of general process steps, it is far more likely to observe fluidity and strategy evolution over time from the first conceived strategy as remediation progress occurs. The chapter concludes with a brief discussion of how the strategy at the Hanford Site has evolved to provide a singular example of what this evolution might look like for other complex waste sites.

Muller, Katherine A.↗
DOE OSTI2022

Development of a three-dimensional APOLLO3 neutrons deterministic scheme for the CABRI reactor

CABRI is an experimental reactor to study the fuel behavior during reactivity injection transients. These transients being highly multiphysics, the development of suitable modeling and simulation tools to simulate them is important for the optimization of the tests and the control of the experimental conditions. This paper focuses on the development of an APOLLO3 deterministic core calculation tool dedicated to the CABRI transient analysis. It represents the first stage of the incremental process for the implementation of a multiphysics time-dependent modeling of the CABRI transient. The neutron calculation scheme is based on a classical two-step approach. The first step consists of a 281-energy group calculation flux with the TDT-MOC (Method Of Characteristics) solver for cross-section space and energy (23 groups) collapsing for the CABRI different assembly clusters. The bias on a 2D core neutron calculation due to the self-shielding calculation and collapsing on a restricted pattern are investigated thanks to a comparison with a direct full 2D calculation on a quarter of core. The second step relies on a pin-resolved transport 3D transport core calculation with the SN solver MINARET. A progressive numerical validation process is followed to quantify the calculation biases on reactivity and reaction rates at each step using reference calculations with the stochastic code TRIPOLI4. The next development stage toward a multiphysics scheme will be the implementation of the 3D-kinetics equation resolution and the coupling with a core thermal-hydraulics model. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Accelerated coupled Monte Carlo-Thermal hydraulic calculations using a hybrid GTF-diffusion-based prediction block: first results

Accurate predictions of spatial power and temperature distributions require the coupling of a neutron transport solver with a thermal-hydraulic (TH) feedback. Nowadays, Monte Carlo (MC) codes are widely coupled to TH solvers, typically via a Picard iteration (PI) method, due to the higher fidelity that such frameworks can produce. To speed up a PI, a prediction step can produce an improved initial guess for a source distribution and feed it to the MC code. Recent work investigated a prediction step that uses generalized transfer functions (GTFs) to predict the macroscopic cross sections' variations following a perturbation in TH properties, such as coolant density. The previous method also relied on first order perturbation (FOP) theory to predict perturbed power profiles, rather than using an expensive MC iterate. The implemented FOP method relied on generating a fission matrix from which the forward and adjoint Eigenmodes were extracted and later used to for power calculations. The generation of the fission matrix can introduce a significant computational overhead, therefore undermining the performance of the proposed hybrid technique when applied to high-dimensional problems, e.g., full core calculations. This work attempts to improve the GTF-FOP prediction step by replacing the FOP solver with a nodal diffusion solver, thus eliminating the need to calculate a fission matrix. The GTF-diffusion step was tested for various moderator density perturbations. In each case, the predicted power distribution showed good agreement with the reference case. The latter is attributed to the generally good prediction of most spatially distributed macroscopic cross sections, except the transport cross section, which will become the focus of future work. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Coupling Subsurface and Above-Surface Models for Optimizing the Design of Borefields and District Heating and Cooling Systems

Accurate dynamic energy simulation is important for the design and sizing of district heating and cooling systems with geothermal heat exchange for seasonal energy storage. Current modeling approaches in building and district energy simulation tools typically consider heat conduction through the ground between boreholes without flowing groundwater. While detailed simulation tools for subsurface heat and mass transfer exist, these fall short in simulating above-surface energy systems. To support the design and operation of such systems, the study developed a coupled model including a software package for building and district energy simulation, and software for detailed heat and mass transfer in the subsurface. For the first, it uses the open-source Modelica Buildings Library, which includes dynamic simulation models for building and district energy and control systems. For the heat and mass transfer in the soil, it uses the TOUGH simulator. The TOUGH family of codes can model heat and multi-phase, multi-component mass transport for a variety of fluid systems, as well as chemical reactions, in fractured porous media. The study validated the coupled modeling approach by comparing the simulation results with one from the g-function based ground response model. It then looked into effects when the water table and the regional groundwater flow are considered in the ground, from the perspective of heat exchange between borehole and ground, and the electrical consumption of the district heating and cooling systems. To access the simulation models, please find the links in the submission: -- For coupled approach validation: see model Buildings.Fluid.Geothermal.Borefields.Examples.BorefieldsWithTough and Buildings.Examples.DistrictReservoirNetworks.Examples.Reservoir3Variable_TOUGH from the "Modelica Building Library" resource, branch issue1495_tough_interface, commit a2667c0. -- For the study of the effect of water table: see model Buildings.Examples.DistrictReservoirNetworks.Examples.Reservoir3Variable_TOUGH from he "Modelica Building Library" resource, branch issue1495_tough_interface_moreIO, commit 760de49. -- For the study of the effect of regional groundwater flow: see Buildings.Examples.DistrictReservoirNetworks.Examples.Reservoir3Variable_TOUGH from he "Modelica Building Library" resource, branch issue1495_tough_interface_moreIO_3D, commit c2a2d2a. The coupling interface script "GrounResponse.py" can be found from the above links in the folder Buildings/Resources/Python-Sources. Also, the needed files for TOUGH simulation are in the folder Buildings/Resources/Python-Sources/ToughFiles that can be accessed through the above links. A brief description of these files is given below; detailed specifications for the first three files may be found in the TOUGH3 Users Guide (Jung et al., 2018) https://tough.lbl.gov/documentation/tough-manuals/. (1) INCON - initial conditions for each grid block (2) INFILE - main input file with material properties and control parameters (3) MESH - description of the computational grid (4) readsave - Modelica/TOUGH interface program: read the final output of TOUGH simulation after TOUGH time step and prepare for transfer to Modelica for next Modelica time step (5) readsave.inp - input parameters for program readsave (6) writeincon - Modelica/TOUGH interface program: write the output of Modelica after Modelica time step and prepare for transfer to TOUGH as initial conditions for the next TOUGH step (7) writeincon.inp - input parameters for program writeincon

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

ADVANCED THERMAL-HYDRAULIC MODEL OF HEAT RECOVERY STEAM GENERATORS

Steam-side oxidation at elevated temperatures in heat recovery steam generators (HRSGs) can lead to overheating of local tubes, potential oxide scale exfoliation, and damage to critical equipment. Predicting the oxide growth distribution requires detailed knowledge of the distribution of tube metal temperatures. To address these challenges, a computational fluid dynamics (CFD) model of a high-pressure superheater (HPSH) was developed within the Siemens’ STAR-CCM+ CFD commercial software. The HPSH section of the steam generator was selected for modeling because of its high oxidation rates.The model development included several steps. In the first step, an oxidation model based on a parabolic oxidation relationship was implemented. The oxidation growth predicted by the model was then verified for a full-load boiler operation case. In the second step, a three-dimensional CFD model was developed to account for the thermal and flow physics involved in HRSGs. The CFD model was then verified and validated on a simplified geometry that contained six row-tubes which mimicked the tube arrangements of an HPSH section. Numerical results compared well with published experimental results. In the third step, the oxidation model was coupled to the HRSG’s CFD model, and a comparison study was performed for two cases: (a) regular finless tubes and (b) finned tubes. Preliminary results showed that the oxide thickness predicted by the case with tube fins was higher compared to that of the finless tube case, thus demonstrating the need to model the effects of the tube fins on oxide thickness.

Panicker, Nithin↗
DOE OSTI2021

Superconducting RF Gun with High Current and the Capability to Generate Polarized Electron Beams

High-current low-emittance CW electron beams are indispensable for nuclear and high-energy physics fixed target and collider experiments, cooling high energy hadron beams, generating CW beams of monoenergetic X-rays (in FELs) and gamma-rays (in Compton sources). Polarization of electrons in these beams provides extra value by opening a new set of observables and frequently improving the data quality. We report on the upgrade of the unique and fully functional CW SRF 1.25 MeV SRF gun, built as part of the Coherent electron Cooling (CeC) project, which has demonstrated sustained CW operation with CsK2Sb photocathodes generating electron bunches with record-low transverse emittances and record-high bunch charge exceeding 10 nC. We propose to extend the capabilities of this system to high average current of 100 milliampere in two steps: increasing the current 30-fold at each step with the goal to demonstrate reliable long-term operation of the high-current low-emittance CW SRF guns. We also propose to test polarized GaAs photocathodes in the ultra-high vacuum (UHV) environment of the SRF gun, which has never been successfully demonstrated in RF accelerators.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Geochemical Impact of Acid Spearhead and Slickwater Stimulation on Wolfcamp Shale from the Hydraulic Fracturing Test Site

The Hydraulic Fracturing Test Site 1 (HFTS-1) was a field study performed in the Wolfcamp Formation in the West Texas Permian (Midland) Basin, USA, with a focus on improving the efficiency of hydraulic fracturing. Investigating site-specific rock-fluid geochemical interactions during hydraulic fracturing is an important step to understanding the impact on formation shale porosity, permeability, and long-term shale gas production. During field operations in this region, hydraulic fracturing fluid (HFF) injection usually starts with a concentrated acid spearhead for rapid rock dissolution, followed by the injection of near-neutral pH slickwater containing chemicals and proppants. A multistep sequential injection approach was used to investigate different stages of rock-fluid interactions. The carbonate content in the host rock is important when acid spearhead is considered, as carbonate mineral dissolution is rapid and can result in porosity and permeability changes in the shale matrix. Here, in this study, we designed flow-through experiments using fractured carbonate-rich and clay-rich Wolfcamp shale cores with (1) a short-time acid soaking step and (2) a long-term slickwater flow-through step to simulate the injection method used at HFTS-1. The fluid chemistry was analyzed. A thorough mineralogical progression [e.g., Calcium (Ca) dissolution and iron (Fe) redox progression] in the cores during HFF injection was also characterized and imaged by synchrotron microprobe. Reactive transport modeling was performed based on the experimental setup. The results showed that the acid spearhead is a crucial step in creating a reaction front by mineral dissolution, especially in carbonate-rich shales. A slight layer of ferrihydrite precipitated during the slickwater flow-through period. This study provides insights into potential geochemical impact due to hydraulic fracturing operations in the Permian Basin.

clastic rock↗
DOE OSTI2020

DECOVALEX-2023 Task E Specification (Rev. 0)

This report is the Task E specification (Revision 0) for DECOVALEX-2023. Task E is focused on understanding thermal, hydrological, mechanical and chemical (THMC) processes, especially related to predicting brine migration in heated salt. The main test case being used is the ongoing Brine Availability Test in Salt (BATS) heater test located underground at the Waste Isolation Pilot Plant (WIPP) in Carlsbad, New Mexico. This report provides short motivational background, a summary of relevant experiments and data, and a step-by-step plan for the analysis by the teams participating in Task E (Rev. 0 includes detailed description of steps 0 and 1). This document will be revised, and more detail will be added to later steps during DECOVALEX-2023.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Integrated Optimization and Control of a Hybrid Gas Turbine/sCO 2 Power System

During phase-I, the project team led by Echogen Power Systems (EPS) had two primary objectives based on investigating the application of gas turbines with supercritical carbon dioxide (sCO 2 ) power cycles. The first objective was to improve the overall efficiency and performance of a hybrid gas turbine/sCO 2 power system through a joint optimization of the two subsystems (gas turbine and sCO 2 power cycle) using non-linear optimization techniques that simultaneously evaluate thermal performance of the combined cycle. The hybrid power system included several points of interaction, including (but not limited to) gas turbine exhaust, fuel heating, inlet chilling and turbine cooling. The second objective was to establish a baseline transient response model of the hybrid power system and a notional microgrid and begin steps to integrate the control systems of the three major elements (gas turbine, sCO 2 cycle and grid controller). The project team established a baseline performance for a combined cycle power plant using a production gas turbine and scaled sCO 2 power cycle only utilizing exhaust heat recovery. Echogen’s non-linear techno-economic optimization code was extended by adding gas turbine component models derived from a in-house developed gas turbine design code. With the two cycles coupled by the gas turbine exhaust, design parameters of both cycles were allowed to vary simultaneously to determine performance opportunity versus isolated designs. Returning to the baseline gas turbine/sCO 2 power cycle transient models: Echogen had in-house developed sCO 2 cycle transient model in GT-Suite system simulation software, and had partnered with Siemens Finspång for gas turbine transient model, and Siemens PTI group to provide micro-grid load profile as well as hybrid power cycle generated load (power and frequency) analysis. The transient model for the SGT-750 Siemens gas turbine was a “black-box” functional mock-up interface (FMI) model developed by Siemens Industrial Turbomachinery in Finspång, Sweden. The SGT-750 is a twin-shaft gas turbine that produces 40 MW electricity with an efficiency of about 40% at ISO conditions. At 100% gas turbine throttle (load), the SGT-750 has average exhaust conditions of 114.6 kg/s and 469.8°C. The transient model for sCO 2 power cycle was developed by Echogen in GT-SUITE 1D system simulation software platform. The basic CO 2 flow circuit has single-shaft turbomachinery with net 11.5 MW electrical power output at design conditions. The power turbine has a double-ended shaft with one end connected to synchronous generator through a fixed-ratio gearbox. The other end of power turbine is connected to the compressor through a continuously variable transmission. The major components of the sCO 2 power cycle modeled include air cooled condenser/cooler, CO 2 compressor, recuperator, two waste heat exchanger coils, power turbine, continuous variable transmission, gearbox and generator. Integration of SGT-750 transient model and sCO 2 power cycle transient model was done in Matlab Simulink. In the integrated model, the gas turbine and sCO 2 power cycle interacted at two points, first one being the gas turbine exhaust gas flow rate and temperature, which were inputs to sCO 2 power cycle model. The second point was the distribution of micro-grid load demand signal between the SGT-750 generator and sCO 2 cycle generator. For a given combined-cycle load demand, the gas turbine load demand was equal to the total demand minus the sCO 2 cycle power generated. In the present study the integrated model was simulated for two cases of grid load demand: (i) for a step change, both positive-step and negative-step, in grid load demand (ii) for a micro-grid load demand curve provided by Siemens PTI group. Finally, the time series plots representing load demand versus integrated system response were presented including the sCO 2 power cycle control system performance plots. The actual generated power and frequency of both the generators, gas turbine and sCO 2 power cycle, was supplied to Siemens PTI group for dynamic grid assessment, results of which are provided in appendices.

03 NATURAL GAS↗
DOE OSTI2021

Quarter 4 Report: Report on Final Findings and Opportunities for Future Work in the Use of Mixed Precision in Iterative Solvers

The fourth quarter of the project was spent developing an error analysis of the s-step Lanczos and CG algorithms. Our theoretical bounds and numerical experiments show that the numerical behavior of the algorithm can be significantly improved by using extra precision in a small part of the computation related to the computation and application of the Gram matrix. We have published a technical report which includes all steps of the analysis [8]; a shortened version for journal submission is in preparation. We plan to submit this paper in the following weeks. Activities related to this also include a collaboration with Ichitaro Yamazaki on gathering performance results for these new mixed precision s-step Krylov subspace methods using single/double precision on GPUs. Namely, we would like to obtain performance results that show that the performance overhead of using double the working precision in these select computations is minimal. Other activities include attending biweekly xSDK meetings and presenting a pitch talk on this work to the group on February 25, 2021. In the remainder of the document, we summarize our findings on the potential for mixed precision in classical Krylov subspace methods and s-step Krylov subspace methods, as well as key opportunities for future work.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Defender Policy Evaluation and Resource Allocation against MITRE ATT&CK Data and Evaluations

Protecting against multi-step attacks of uncertain duration and timing forces defenders into an indefinite, always ongoing, resource-intensive response. To effectively allocate resources, a defender must be able to analyze multi-step attacks under assumption of constantly allocating resources against an uncertain stream of potentially undetected attacks. To achieve this goal, we present a novel methodology that applies a game-theoretic approach to the attack, attacker, and defender data derived from MITRE´s ATT&CK ® Framework. Time to complete attack steps is drawn from a probability distribution determined by attacker and defender strategies and capabilities. This constraints attack success parameters and enables comparing different defender resource allocation strategies. By approximating attacker-defender games as Markov processes, we represent the attacker-defender interaction, estimate the attack success parameters, determine the effects of attacker and defender strategies, and maximize opportunities for defender strategy improvements against an uncertain stream of attacks. This novel representation and analysis of multi-step attacks enables defender policy optimization and resource allocation, which we illustrate using the data from MITRE´ s APT3 ATT&CK ® Framework.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Shear Assisted Processing and Extrusion (ShAPE) of Aluminum Alloy 7075, 2024, and Al-12.4TM

The most common aluminum alloys utilized in the aerospace industry are 7075 and 2024 due to their high strength-to-weight ratio compared to advanced high strength steels and other aluminum alloys. Despite excellent performance, these aluminum alloys have seen limited use outside of the aerospace industry due in part to high cost. If high-performance aluminum extrusions could be made more cost effectively by eliminating energy intensive process steps typical of conventional extrusion, then numerous opportunities exist for more widespread adoption. A key reason for the high cost of 7075 and 2024 extrusions (25-75% higher than 6061) is their slow extrusion speed. 7075 and 2024 are limited to 2 m/min and 3.5 m/min respectively, in contrast to 6061 which can be extruded at 20–80 m/min. In addition to slow speed, aluminum alloys require numerous thermal treatments throughout the extrusion process including homogenization and pre-heating prior to extrusion, and solution heat treating and artificial aging after extrusion. Each of these steps contribute to the total energy consumed during manufacturing of extruded components. This project investigates the use of ShAPE to improve extrusion speed and reduce, or even eliminate, the typical thermal treatments for high strength aluminum alloys, all while improving material performance. The overarching goal of this project was to demonstrate that Shear Assisted Processing and Extrusion (ShAPE) can manufacture high-performance aluminum alloy tubing with lower manufacturing energy and improved mechanical properties compared to conventional extrusion. Unlike conventional extrusion where the billet is rammed against a stationary die using a strictly linear motion, the ShAPE process superimposes a rotational shear force by spinning the die while the billet is plunged. Compared to conventional linear extrusion, the ShAPE process imparts significantly more strain into the feedstock material, which enables the formation of novel microstructures. These microstructures manifest an array of property and process improvements for extrusion of high-performance aluminum alloys. The following accomplishments were achieved for this project: Extrusion of 7075 at 12.2 meters/min compared to 2 meters/min for conventional extrusion; Elimination of 7075 billet homogenization (430 °C for 20 hours) which is required prior to conventional extrusion; Elimination of 7075 billet pre-heating (400 °C for 1 hour) in a separate furnace which is required prior to conventional extrusion; Achieved 7075-T6with yield strength = 595 MPa, ultimate tensile strength = 531MPa, and elongation = 17.4% for extrusions made from unhomogenized billets. Exceeds the ASTM and ASM standard, and typical industry values; Achieved 7075-T5 (i.e., no solution heat treatment) with yield strength = 588 MPa, ultimate tensile strength = 535 MPa, and elongation = 14.8% for extrusions made from homogenized billets; Extrusion of 2024 at 7.4 meters/min compared to 3.5 meters/min for conventional extrusion; Achieved 2024-T8510 yield strength = 522 MPa, ultimate strength = 510MPa, and elongation = 7.1% for extrusions made from wrought billets. Exceeds the ASTM and ASM standard, and typical industry values; Extrusion of Al-12.4TM high-performance aluminum powder directly into tubing, in a single step, which eliminates process steps typical of powder metallurgy extrusion.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Analysis of Nuclear Fuel Cycle Data

Electricity generated using nuclear power accounted for 18.9% of all electricity consumed in the United States in 2021, putting it in third place behind natural gas (38%) and coal (22%) power plants. Nuclear power plants boast a significantly higher uptime or capacity factor—90% and above—compared to 49.1% for coal fired power plants and 56.6% for natural gas power plants. Renewable energy sources, such as solar photovoltaic (PV) and wind electricity, have lower capacity factors: 24.9% and 36.3%, respectively. In addition, nuclear power is cleaner than both coal and natural gas fired power plants. With the passing of the 2022 Inflation Reduction Act, significant tax credits will be claimed by producers of hydrogen with well-to-gate greenhouse gas (GHG) emissions below 0.45 kg CO 2e /kg H 2 . This has sparked interest in using clean sources of electricity, including nuclear power, to generate H 2 via water electrolysis. As uranium is a primary fuel for modern nuclear power plants, the upstream emissions from nuclear fuel production greatly impact the GHG emissions related to all nuclear power end use. Therefore, it is important to accurately determine the upstream emissions associated with the nuclear fuel cycle of nuclear power production in the United States. In this analysis, the nuclear fuel cycle was separated into distinct steps to allow better understanding of the chemical and energy inputs at each step of the fuel cycle. This also provides details of the GHG emissions at each step in the nuclear fuel cycle. The transportation distance for each step of the fuel cycle was updated to account for the locations of uranium processing facilities along the supply chain of the current U.S. nuclear power plants. Finally, all the updated values were incorporated into Argonne National Laboratory’s Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies (GREET) model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗